Apparatus for making metal strips



May 27, 1952 R. M. BRENNAN APPARATUS FOR MAKING METAL. STRIPS 5 Sheets-Sheet l Filed July 27, 1948 L -Wllliu I May 27, 1952 R. M. BRENNAN APPARATUS FOR MAKING METAL STRIPS 3 Sheets-Sheet 2 Filed July 27, 1948 INVENTOR.

Yzf/m HLM@ May 27, 1952 R. M. BRENNAN 2,598,344

A APPARATUS FOR MAKING METAL STRIPS Filed July 27, 1948 3 Sheets-Sheet 3 Patented May 27, 1,9527.

UNITED STATES TENT OFFICE I Claims.

This invention relates to an apparatus for continuous production of thin strip metal.

According to one adaptation of this invention thin flexible bands of suitable material to which spray deposited metal does not firmly adhere under the controlled conditions of the invention are passed in sequence before one or more molten metal spray nozzles in such a manner that a substantially uniform layer thereof is deposited and is stripped therefrom thereafter.

As a modification of the invention a relatively wide not too adherent surface is passed before a crosswise spray with reference to the directional motion of the said relatively wide not too adherent surface and the spray nozzle or gun is 0scillated in synchronism with the motion of the surface so that an overlapping spray deposited layer is produced of substantially uniform thickness.

As a further modification a large roll circumferentially many times the width of a single spray deposit pattern is passed before a series of spray guns to produce an overlapping series of somewhat parallel spray deposits which may be stripped from the roll and which has a substantially uniform thickness.

Spray apparatus suitable for accomplishing the purposes of this invention is described in my pending application 'Serial No. 1,926, filed January 13, 1948, and this application is a continuation-in-part thereof in so far as common subject matter exists.

Conventional molten metal spray apparatus may also be used in conjunction with this apparatus of and according to the methods of this invention to achieve the purposes thereof.

Any thermoplastic meltable material normally solid which becomes fluid under heat and which can be atomized when iluid and which solidies on cooling can be used in conjunction with the apparatus and according to the methods of this invention.

The apparatus of this invention may be also used to make coated or laminated metal strip if control conditions therefor are introduced whereby the coating on a strip of base metal will be uniform in thickness. Thus a strip of cold rolled ordinary commercial steel may be lightly spray deposited with atomized or nely divided nickel particles which are fused thereto to form a lattice work on one side thereof and then a layer of leaded bronze is rolled against the so treated steel surface while the adjacent surfaces to be joined are rendered somewhat plastic condition by surface heating while the non-adjacent surfaces are cooled.

' for laminating a further deposit thereon.

In any case according to my invention a uniform thickness metal strip is produced when the spray deposit is stripped from the moving base.

It is possible to make removable non-uniform thickness layers and strip same from the base material also with apparatus of this invention but this is generally undesirable and wasteful and such strips have generally irregular edges and could only have very specific and relatively few uses.

I find that easier stripping is achieved with certain metals if the deposited strips are sharply bent back and away from the line of travel of base strip. This feature is not shown in the drawings. A parting knife, blade or edge can be of help in smooth stripping also but is not shown, as not always needed.

In case it is desired wide spray deposited strips may be slit and resprayedusing the initial spray deposited strip as may be used as a base band Referring to the drawings which accompany and are a part of this specification:

Fig. I represents in plan an endless band as of stainless steel driven by a preferably variable speed motor I Fig. I over drums I Fig. I spirally so that at least three passes are presented to a metal spray gun I I Fig. I centrally located preferably and away from with reference to the drum l Fig. I over which the endless belt of stainless steel 8 Fig. I passes. The motor I Fig. I drives the drums 'I Fig. I by means of belt 2 Fig. I. The belt 2 Fig. I drives the slip friction clutch 3 Fig. I also which drives the wind-up drum I Il Fig. I onto which the spray deposited built-up strip 9. Fig. I is coiled as it is stripped from` the last turn of the endless belt 8 Fig. I. The endless belt 8 Fig. I spirals around the periphery of the right-hand drum 'I Fig. I in one direction crosswise and spirals around the lefthand drum 1 Fig. I oppositely crosswise spirally. Guides not shown keep the belt 8 Fig. I in proper alignment on the drums 'I Fig. I and with reference to the spray nozzle II Fig. I so that the spray thrown out from the gun I I Fig. I deposits partially on the inner halves of the outside spirals of the endless belt 8 Fig. I and all over the area in front of the nozzle II Fig. I on the centralspiral of the endless belt 8 Fig. I as it passes over the right hand drum 'I Fig. I.

Referring to Fig. II of the drawings which is a longitudinal section of the apparatus of Fig. I like numerals designate like parts in both Fig. I and Fig. II. In Fig. II the metal strip 9 is shown being removed from the endless belt 8 and coiled on the reel III Fig. II. Also in Fig. II a pan I3 is shown into which the endless belt 8 passes for cleaning so that any metal particles remaining thereon may be removed. A stripper knife not shown or scraper may also be used in conjunction therewith. The tank or pan i3 Fig. II may also be used for anodizing the endless belt 3 Fig. II which anodizing prevents too great adherence of the metal strip deposit if the endless belt 8 Fig. II has. a surface of lm forming metal having anodized film formed thereon. As an alternative the tank I3 Fig. II may contain a light lubricant as of silicone lubricant and apply same to one pass of the endless belt 8 Fig. II to prevent too great adherence of the deposited metal strip. The hollow shaft l2 Fig. II is arranged for cooling the drum 1 Fig. II by suitable coolant ywhich in turn assists in keeping the belt 8 Fig. II cool.

Fig. III of the drawings is a plan of an appar ratus according to this invention for passing one or more long but not endless metal bands 2S Fig. III spirally about a largedrum 32 Fig; III which is driven by motor 20 Fig. III by means'of belt 2l Fig. III which drives wind-up clutches 2K2 Fig. III which coils up long band 29 Fig. III forming coil 28A Fig. III thereof and also coils up spray deposited strip 3B Fig. III onto drum 35 Fig. III. The spray nozzle 3| Fig. III deposits spray on the two inside halves of the outside spirals of the band 29 Fig. III about drum 32 Fig. III as well as over the. entire cross-section of the middle pass of the band 29 Fig. III about drum 32 Fig. III so that after the third pass of the band 29 Fig. III about drum` 32 Fig. III a uniform cross-sectioned strip 30 Fig. III has been spray deposited on the band 29 Fig. III and may be removed therefrom to coil up on drum 35 Fig. III.

Fig. IV is a sectional longitudinal view of the apparatus shown in Fig. III and shows more clearly the metal strip spray deposited and being parted 3i) Fig. IV from base stripZS Fig. IV and brake 25 Fig. IV on supply Vcoil 26 Fig. IV which supplies the strip 29 Fig. IV to the drum S Fig. IV for at least triple passage therearound for spray producing the strip 3i! Fig. IV thereon.

No cleaning means for base strip 2S Fig. IV is shown in Figs. III and IV. Cooling means by hollow Yshaft supplied coolant is shown at 3E Fig. III and Fig. IV.

Fig. V is section online E of Fig; IV and illustrates successive buildup of spray deposit to achieve uniform cross-section. Fig. V is a partial view axially of the drum 32 showing'the spiral bands 29 passing thereover and showing the resultant build-Yup of sprayed layers 3S over the spiral bands. t-A illustrates the edge ldeposit on the spiral band as it makes the first pass over the drum 32. Sil-B shows the build-up of a layer all the' way across the top of the second pass of the spiral band over the drum 32 and 3Q shows the completed build-up on the last pass after it has passed before the spray gun 3i Fig. III and illustrates the uniformity in cross-section of the finished porous metal strip.

Fig. VI is a plan of apparatus showing a -relatively wide long band ofbase 4material 48 being passed over drum supported by bearings 5i and fed `from coil d6 on drum 45 supported on bearings 43 held back by brake 53 said strip being drawn by wind-up drum 4I supported by bearings lit driven by slip clutch and pulley A2 through belt 4I from motor 40. As the wide base band is passes over the drum 5B before the spaced spray nozzles 52 an overlapping parallel series of sprayed layers is deposited thereon to form the strip 49 which is wound up onthe' drum 55 sup ported on bearing Q4 driven by belt 6l through clutch 42. The hollow shaft 54 is for circulating coolant through drum 5t to assist in cooling base band QS and facilitate stripping of layer 49 therefrom. It is also contemplated that instead of a single band 48 a number of narrower parallel bands may be used as base for spray depositing layer thereon and these may be coiled in parallel relation and have multiple strips removed therefrom continuously instead of the single wide strip 49.

Sltters not shown may be inserted at and between the edges of parallel base bands to facilitate removal of multiple bands deposited.

Any useable thickness of spray deposited layers may be 'achieved by having successive sets of nozzles build up the amount of metal sprayed or by slowing down or speeding up the rate of travel of the band d8 Figs. VI and VII.

Fig. VII is a sectional view of apparatus shown in Fig. VI using like numerals to designate `like parts.

The nozzles 52 Fig. VI may be conventional spray guns or multiple movable nozzles-attached to spray apparatus explainedandV shown in my pending U. S. patent application Serial No. 1,926, filed January '13, 1948.

Theidensity and porosity of the spray deposited layers are regulatable during.deposition-byfregulating base temperatures, atmospheric temperatures and constituents of the atmosphere.

Subsequent rolling and/or'heat treatment of the mononietalor alloystrip so produced'is-contemplated using this invention if desired. The production of multiple or wide laminatedmetal strips by this apparatus is also contemplated. If laminations are`desired additions to this apparatus are desirable not shown to e'ect better bond of base strip and the deposited metal.

When a wide metal band or parallel-multiple meta1 bands as shown inFig. VI- and Fig. VII have a layer deposited thereon and across the width thereof a certain amount of` edgesprayis lost but it is much less percentagewise than when a single narrow band is sprayed with a single spray device and a single pass and uniform gauge crosswise is not attainable without the overlapping vsprays without great loss of the sprayed metal. Thus in spraying a single band 2" wide with a type E Meteo spray gun as much as 50% of the sprayed ya" wire may be lost-and non-uniform gauge in deposit secured Whereas with the wide band, multiple parallel bands or spiral bands of this apparatus less than l10% of the sprayed metal need be lost under similar conditions.

It is contemplated to produce alloy stripby this apparatus by spraying more than one metal at once and blending them proportionately or by spraying alloyed molten metal. Also it is contemplated to spray other materials -with Vthe metal spray for interlocking and embedmentLif desired.

Instead of the elongated widemetal band shown in Fig. VI and Fig. VII; -anlendless single pass wide metal Aband may be used `lrunning over both the drum 50 and over the-drum 41 continuously Aand having-the deposit stripped therefrom continuously. YThis endlessbeltor band maybe anodised or otherwise ltreated toy prevent" too great adherence and a scraper may be installed onftheiinside edges of the drum 58 to scrape` oi excess spray deposit from the edges ofthe drum. The stripped metal t9 Fig. VII may also be 'passed *cveranother set of rolls for spraying additionally maximumthicknessat thecenter thereoffamoving. belt of. ai. width .ofc approximately enel-half that of said deposit, and a-rotatable drumadjacent said spray depositing device, said belt being wound in at least threehelical convolutions about said drum, said spray depositing device forming as .taperddepost 0n a center .-.convolutiQn-,and a tapered deposit on the adjacent edge of each adjacent convolution, said moving belt successively passing through different zones of said spray section to overlap upon said belt a plurality of cross-sectionally tapered deposits into a layer of substantially uniform section.

2. Apparatus for producing strip metal comprising a molten metal spray depositing device which makes a spray eld having an elongated transversely tapered cross-sectional deposit of maximum thickness at the center thereof, a moving belt of a width of approximately one-half that of said deposit, and a pair of rotatable drums one of which is adjacent said spray depositing device, said belt being wound in at least three helical convolutions about each of said drum and being looped therebetween with the portions of the belt extending between said drums being oiset axially of the drums from each other, said spray depositing device forming a tapered deposit on a center convolution and a tapered deposit on the adjacent edge of each adjacent convolution, said moving belt successively passing through different parts of said spray iield to overlap upon said belt successive cross-sectionally tapered deposits into a unitary layer of substantially uniform section.-

3. Apparatus for producing strip metal comprising a molten metal spray depositing device which makes a spray field forming a transversely tapered deposit of gradually decreasing edge thickness, a belt of a width of approximately onehalf that of said deposit, means for moving said belt through said spray field, and means for producing at least three helical convolutions of said belt in said spray field which convolutions are aligned and in edge contact, said convolutions being centered in said spray field.

4. Spraying apparatus comprising a longitudinally moving belt and drive means therefor, a metal spray depositing device producing a spray field directed toward one face of said moving belt, such spray field being wider thansuch one face of said belt, means supporting said belt for simultaneous longitudinal movement of longitudinally spaced sections thereof in side by side relation past such spray field, the combined width of the adjacent sections of said belt being greater than that of such spray eld whereby the spray metal from said device is deposited on one face of said belt without substantially any overspray.

5. Apparatus for producing strip metal across the entire width of a longitudinally moving belt, comprising means for driving said belt, a molten metal spray depositing device producing a spray eld directed toward one face of said moving belt. such spray field being wider than such one face of... said beit. means sin;porti-I1,ffifr sai-d,v belt; forvv simultaneous lonw dinal t tudnallyspaceds tion relation pastsuc spraiield, theI combined widthbfa-the adjacenft{sections,of,said-belt ceeding that ofesuchaspra -eIdand be it l of- -said; stelt@ withgut ,substantiallyAA any, overspray; v A

6;- separates-...fm nipducinetexible .str-il meta. ccmprisinga, .mglten vice lwhich makes,an; fe1o and. drive fmeanstherefjor-to move said belt so as to have a layer of metal sprayed thereonto by said device, and means supporting longitudinally spaced. sections e of said Abelt insadjacentlelation and in longitudinally curved form-oppositesaidE device whereby cross-sectionally tapered deposits are overlapped on such longitudinally curved sections and means supporting said belt in at least a partially straightened form, subsequent to spraying of metal thereonto, whereby to facilitate stripping of the spray deposited layer from said belt to produce flexible strip metal.

7. Apparatus for producing strip metal comprising a molten metal spray depositing device which makes a spray eld having a transversely tapered cross-section deposit of maximum thickness at the center thereof, a moving belt of a width less than that of said spray field, and a rotatable drum, said belt being looped in such a number of convolutions around said drum that an aggregate of at least two widths of said belt are exposed to said spray field, said spray depositing device forming a tapered deposit within the outside edges of the aggregate, said moving belt successively passing through zones of different density of said spray eld to overlap upon said belt successive cross-sectionally tapered deposits into a layer of substantially uniform thickness.

8. Apparatus for producing strip metal comprising a molten metal spray depositing device which makes a spray field having a transversely tapered cross-sectional deposit of maximum thickness at the center thereof, a moving belt of a width of less than that of said spray field, a pair of rotatable drums one of which is adjacent said spray depositing device, said belt being Wound in at least two convolutions about each of said drums with the portions of the belt extending between said drums being offset axially of the drums from each other, said spray depositing device forming a tapered deposit on a portion central of said convolutions and extending to within their outside edges, said moving belt successively passing through zones of dierent density of said spray field to overlap upon said belt successive cross-sectionally tapered deposits into a unitary layer of substantially uniform thickness, and means for stripping said unitary layer from said belt.

9. Apparatus for producing strip metal cornprising a molten metal spray depositing device which makes a spray eld forming a transversely tapered deposit of gradually decreasing thickness toward the edge thereof, a belt of a width less than that of said spray eld, means for moving said belt through said spray field, and means for producing at least two convolutions of said belt 7 in said spray field which convolutions are aligned and substantially in edge contact.

10. Spraying apparatus comprising a longitudinally moving belt and drive means therefor, means supporting said belt for simultaneous longitudinal movement of longitudinally spaced sections thereof in side-by-side relation, a metal spray depositing device producing a spray eld directed toward a portion of said side-by-sidesections, said spray field being Wider than one of such sections of said belt, the combined width of the adjacent sections of said belt being greater than that of said spray ileld whereby the spray metal from said device is deposited on said one section of said belt without substantially any overspray beyond the outside edges of said adjacent sections.

ROBERT M. BRENNAN.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENT Number Number Name Date Schoop Feb. 9, 1915- Lane Dec. 28, 1926 Johnson et al Apr. 24, 1934 Schellenger Nov. 17, 1936 Merle Sept. 13, 1938 Merle Sept.,13, 1938 Reid Sept.,.5, 1939 Stossel May 5, 1942 Merle June 9, 1942 Leckie et al. July 2l, 1942 Batcheller Jan. 28, 1947 FOREIGN PATENTS Country Date Great Britain July 8, 1926 

